Sling and method of forming same

Abstract

A medical sling for supporting an anatomical feature having ends that are tapered using a folding fixture and then thermoset. The thermoset ends hold the bunched or folded shape thus allowing the ends to be removed from the fixture and placed into a mold assembly where anchors are molded over the ends.

What is claimed is: 
     
       1. A method of forming a medical sling device comprising:
 providing a rectangular strip of material having two end portions and an elongate body between the two end portions; 
 tapering at least one of said two end portions without removing said material therefrom by bunching said material in such a manner a terminus of said at least one end portion has a smaller width than an intersection between said at least one end portion and said elongate body, wherein bunching said material comprises pulling said rectangular strip through a fixture assembly having a tapered circular end comprising a wave-form opening; 
 thermosetting said at least one end portion such that said at least one end portion maintains said smaller width when unconstrained; 
 placing said at least one end portion in a mold; 
 forming an anchor around said terminus. 
 
     
     
       2. The method of  claim 1  wherein said bunching said material results in a waveform. 
     
     
       3. The method of  claim 1  wherein said fixture assembly comprises:
 a fixture bottom having a groove with a wide end and a narrow end, the narrow end having a curved form with gaps on either side of said curved form; 
 a fixture top having a groove with a wide end and a narrow end, the narrow end having a center fin and a curved form on either side of the center fin; 
 wherein when said fixture top is placed on said fixture bottom and aligned therewith, said center fin points down toward said fixture bottom curved form, thereby creating a wave-like gap through which said rectangular strip may be pulled to create said smaller width in said at least one end portion. 
 
     
     
       4. The method of  claim 3  wherein said fixture further comprises a shaping rod extending from said narrow end of said groove. 
     
     
       5. The method of  claim 1  wherein thermosetting said at least one end portion such that said at least one end portion maintains said smaller width when unconstrained comprises:
 pulling said rectangular strip through said fixture assembly to create a waveform; 
 pulling said waveform further and onto a shaping rod; and, 
 heat-shrinking tubing over said waveform to form said waveform into the shaping rod to create a crescent-shape. 
 
     
     
       6. The method of  claim 5  further comprising removing said tubing prior to placing said at least one end portion in said mold. 
     
     
       7. A method of forming a medical sling device comprising:
 providing a strip of material having two end portions and an elongate body between the two end portions; 
 tapering at least one of said two end portions without removing said material therefrom by creating a wave-like configuration in said material such that a terminus of said at least one end portion has a smaller width than an intersection between said at least one end portion and said elongate body, wherein tapering at least one of said two end portions without removing said material therefrom further comprises pulling said strip of material through a fixture assembly having a tapered circular end comprising a wave-form opening; 
 placing said at least one end portion in a mold; 
 forming an anchor around said terminus. 
 
     
     
       8. The method of  claim 7  further comprising thermosetting said at least one end portion such that said wave-like configuration is maintained while placing said at least one end portion in said mold. 
     
     
       9. The method of  claim 7  wherein said fixture assembly comprises:
 a fixture bottom having a groove with a wide end and a narrow end, the narrow end having a curved form with gaps on either side of said curved form; and, 
 a fixture top having a groove with a wide end and a narrow end, the narrow end having a center fin and a curved form on either side of the center fin; 
 wherein when said fixture top is placed on said fixture bottom and aligned therewith, said center fin points down toward said fixture bottom curved form, thereby creating a wave-like gap through which said strip may be pulled to create said wave-like configuration in said at least one end portion. 
 
     
     
       10. A medical sling comprising:
 an elongate strip of material having two ends and a support portion between said two ends, wherein said two ends and said support portion comprise a uniform cross-sectional material of said elongate strip; 
 wherein each of said two ends comprise thermoset portions having a crescent shape; and, 
 over-molded anchors positioned over said thermoset portions; 
 wherein each anchor comprises a cavity having asymmetric surfaces and said cavity expands between a proximal end and a distal end of each anchor. 
 
     
     
       11. The medical sling of  claim 10  wherein said anchors each comprise:
 a body; 
 tissue-grabbing features extending outwardly from said body. 
 
     
     
       12. The medical sling of  claim 11  wherein said tissue grabbing features comprise at least one wing having a leading edge and a trailing edge and wherein the leading edge sweeps from said body back to said trailing edge. 
     
     
       13. The medical sling of  claim 12  wherein said trailing edge extends forward from said leading edge to a lateral edge. 
     
     
       14. The medical sling of  claim 13  wherein said lateral edge extends perpendicularly from said body to said trailing edge. 
     
     
       15. The medical sling of  claim 10  wherein said elongate strip of material comprises a rectangular shape prior to said two ends being formed into said crescent shape. 
     
     
       16. The medical sling of  claim 10  wherein said crescent shape creates a taper in said elongate strip near said two ends. 
     
     
       17. The medical sling of  claim 10  wherein said anchors each further comprise said cavity useable to receive an implantation device. 
     
     
       18. The medical sling of  claim 10  wherein said two ends are thermoset into said crescent shape that partially surrounds said cavity. 
     
     
       19. A method of forming a medical sling device comprising:
 providing a rectangular strip of material having two end portions and an elongate body between the two end portions; 
 tapering at least one of said two end portions without removing said material therefrom by bunching said material in such a manner a terminus of said at least one end portion has a smaller width than an intersection between said at least one end portion and said elongate body; 
 wherein bunching said material comprises pulling said rectangular strip through a fixture assembly; 
 wherein said fixture assembly comprises:
 a fixture bottom having a groove with a wide end and a narrow end, the narrow end having a curved form with gaps on either side of said curved form; 
 a fixture top having a groove with a wide end and a narrow end, the narrow end having a center fin and a curved form on either side of the center fin; 
 wherein when said fixture top is placed on said fixture bottom and aligned therewith, said center fin points down toward said fixture bottom curved form, thereby creating a wave-like gap through which said rectangular strip may be pulled to create said smaller width in said at least one end portion; 
 
 thermosetting said at least one end such that said at least one end maintains said smaller width when unconstrained; 
 placing said at least one end portion in a mold; 
 forming an anchor around said terminus. 
 
     
     
       20. The method of  claim 19  wherein said fixture further comprises a shaping rod extending from said narrow end of said groove. 
     
     
       21. A method of forming a medical sling device comprising:
 providing a rectangular strip of material having two end portions and an elongate body between the two end portions; 
 tapering at least one of said two end portions without removing said material therefrom by bunching said material in such a manner a terminus of said at least one end portion has a smaller width than an intersection between said at least one end portion and said elongate body; 
 wherein bunching said material comprises pulling said strip through a fixture assembly; 
 wherein said fixture assembly comprises: 
 a fixture bottom having a groove with a wide end and a narrow end, the narrow end having a curved form with gaps on either side of said curved form; and, 
 a fixture top having a groove with a wide end and a narrow end, the narrow end having a center fin and a curved form on either side of the center fin; 
 wherein when said fixture top is placed on said fixture bottom and aligned therewith, said center fin points down toward said fixture bottom curved form, thereby creating a wave-like gap through which said strip may be pulled to create said wave-like configuration in said at least one end portion.